Twin Heat Module

Transcription

Twin Heat Module

Table of Contents
Power Source ……………………………….............................…………………………..
Twin Heat Module ……………………...………………………….............................…..
Controllers ……………………………………………………….............………………..
Recorders ……………………………………………………………….............…………
Strip Chart
Digital Paperless
Chart Paper and Ribbons
1
2
3
4
Power Source Parts ……………………………………………….............……………… 6
Casters
Circuit Breakers
Contactors
Electrical Connections
Fans and Filters
Fuses and Fuse Holders
Hardware
Indicator Lights
Lugs
Panel Meters
Relays
Strain Reliefs
Switches
Transformers
Power Cabling …………………………….............……………………………………… 8
Splitters
Triple Cable Sets
Power Cable
Camlock Connectors ……………………………………………............……………….. 9
150-Amp
300-Amp
Thermocouple …………………………………………………………............…………. 10
Attachment Unit (TAU)
Connectors
Jack Panels
Sheathed Thermocouples
Wire
Test Equipment ……………………………………...…………….............……………... 13
TC-100 Calibrator
Brinell Hardness Test Kit
Heaters …………………………………………………………………….............……… 14
Flexible Ceramic Pad (FCP) Heaters (80 and 60VAC)
Repair Kits
Insulation …………………………………………………………………….............…… 16
Blanket (RCF and non-RCF)
Cooperknit
Meshed Mat
Insulation Pad
Insulation Attachment ………………………………………………….............……...… 17
Banding and Clips
Fiberglass Tape
Iron Wire
Stud Welder and Accessories
Stud Welding Pins & Washers
TISI-12.1
Power Source
Description
The ability to control temperatures precisely is the key to
accurate heat treatment. The Team Industrial Services,
Inc. (TISI) 6-way control console is designed to provide
six independently controlled, low voltage, high current
outputs which precisely control the work piece
temperature.
Length
Width
Height
Weight
Primary Voltage
Standard
International
Secondary Voltage
Power Out, Fan-Cooled
24 inches
24 inches
48 inches
(56 inches with casters)
850 - 900 lbs.
480 VAC
380/415/440/480/575 VAC
65/85 VAC
72 KW
Safety Is Built In
• 125-amp circuit breaker for primary power connection.
• 5-amp circuit breaker safety switch in case of
overloading on control circuit.
• 3/4-amp circuit breaker protection for each secondary
contactor.
• Over-temperature protection of main transformer coils
(275°F/135°C temp. trip).
09010103
Features
• Enclosure - The stainless steel enclosure is supported by a 1-1/2 inch
tubular frame for strength and stability. A fold-down door
protects the electronic components from damage.
• Mounting - Each console comes standard with 6-inch steel swivel
casters with brakes on the front two wheels. The casters can
be replaced with skid plates that are mounted to the bottom of
the machine.
• Output Control - The START/STOP switch on the 6-way console
controls the output voltage of the machine to prevent
unintentional power being sent to the heaters on the work piece.
ITEM
1
2
3
4
5
6
DESCRIPTION
6-way Power Console
Triple Cable Set
Thermocouple Wire Extension Assembly
Splitter Assembly
Heating Elements
Thermocouple (from work piece)
NOTE: Items 2 through 6 must be ordered
separately depending on job requirements
5
4
1
6
Options To Fit Your Needs
3
• Local control - Six independent heating cycles can be manually controlled.
• Remote control - Six individual programmable zone controllers that contain
2
custom firmware to facilitate setpoint programming.
• Temperature recording - A 6-way console is also available with a 12-point
or 24-point temperature recorder.
• Customized units available - The 6-way power source can be customized
to fit most heat treatment requirements.
Part Number
Description
Standard
International
09009901
09009902
6-way, Manual Control
09010101
09010102
6-way, Manual Control with 12-point Recorder
09009903
09009904
6-way, Programmable Control
09010103
09010104
6-way, Programmable Control with 12-point Recorder
See POWER SOURCE PARTS for replacement parts
Contact your TISI sales representative for more information.
1
TISI-12.1
Twin Heat Module
Description
The Twin Heat Module (THM) uses the output of any AC or DC welding machine or transformer to provide up to two independent
channels of temperature control for heat treatment. This power is typically supplied by a 65 or 85 VAC power source with a 300amp per zone capacity.
The THM includes temperature controllers, contactor control switches and thermocouple output sockets to facilitate temperature
recording. The THM also has the option of a 2-pen temperature recorder. A 16-gauge stainless steel case protects unit components
during field operation.
Without recorder (with recorder)
Length
16 3/4 inches (19 inches)
Width
10 3/8 inches (11 1/4 inches)
Height
11 3/4 inches (12 inches)
Weight
27 lbs. (36 lbs.)
On-Site Heat Treatment Is Convenient With The THM
• The small size makes the unit suitable for use in confined spaces.
• Portability allows the THM to be moved quickly to widely
separated locations on a job site.
Electrical Specifications
Power circuit to heaters
Input/output voltage
Input/output current
Control circuit, input
Voltage
Control circuit, auxiliary output
Voltage
Current
Temperature controller
Temperature range
Thermocouple
Part Number
09002800
09002900
09007800
09007900
6-60 VDC up to 220 VAC
300-amp
120 VAC, 50-60 Hz
120 VAC, 50-60 Hz
25-amp (control circuit protected
at 5-amp breaker total)
09002900
0-2400°F
Type K
Description
Twin Heat Module, Manual Control
Twin Heat Module, Programmable Control
Twin Heat Module, Manual Control with 2-pen Recorder
Twin Heat Module, Programmable Control with 2-pen Recorder
The following accessories are necessary to connect to a power source:
29001000
Feed/Return Cable with Lug and 300-amp connector, 10'
or
29001002
Feed/Return Cable with 300-amp connectors, 10'
29002004
Power Cable, 110 VAC, 10' (other sizes available)
Replacement parts for the Twin Heat Module:
Part Number Description
58012200
UDC-2500 Controller, Manual Control
58012900
UDC-3500 Controller, Programmable
50000300
Indicator Light, Red
57004301
Circuit Breaker, Panel Mount, 5A
54008300
Handle for Front
54008900
Handle, Fold down for Top
09002500
Rubber Feet for Base
TISI-12.1
Part Number
49008002
49008003
59001300
56004700
56000200
56007900
56007400
2
Description
TC Jack Panel, Numbered Dual 1
TC Jack Panel, Numbered Dual 2
Contactor, 1-pole, 300A, 120V
300-amp Panel Mount Connector, Male
300-amp Panel Mount Connector, Female
110 VAC Auxiliary Output Receptacle
110 VAC Supply Input Receptacle
Controllers
Description
Each zone in a 6-way power source and Twin Heat Module is controlled by a Universal Digital Controller (UDC). The UDC-2500
model which replaced the UDC-2300 model provides basic manual control using the arrow keys to increase or decrease the rate.
The programmable UDC-3500 model which replaced the UDC-3300 model has set point programming (SPP) capabilities that allow
up to five programmed segments. The unique feature of the available TISI UDC-3500 model is that it has a special firmware
program which simplifies the programming process. Both models are easy to program, operate and read. All configurations and
alignments are completed prior to shipment so that upon receipt, the controller can be placed immediately into service. Please note
that if the new controller is replacing a previous model, minor rewiring will be required to install.
• Convenient to configure - The operator can increase or decrease the local setpoint, select local or remote operating mode,
or momentarily display information about the current process with simple keystrokes.
• A bright, dedicated display performs two functions. The upper display is dedicated to the process variable during normal
operation. Straightforward prompts in English allow easy adjustments to the setpoint, process variable, deviations and
output values with minimum time and effort, which are shown on the lower display. Status indicators display degrees
Fahrenheit, remote or local operation and alarm and output conditions.
• The vacuum fluorescent display clearly presents data. Unlike an LED screen, the vacuum fluorescent display is easily
readable in direct sunlight.
• The well-designed keyboard encourages quick and accurate data entry.
• Universal inputs are accepted: Nine thermocouple types, RTDs, mA, mV and voltage inputs can be configured simply.
Safety features are programmed into the unit to protect operating information.
• Thermocouple failsafe ensures the integrity of data-configurable upscale or downscale burnout or failsafe output level.
• Reliable performance is immune to high noises. The unit provides reliable, error-free control in industrial environments that often
disturb highly noise-sensitive digital equipment.
• Input signal smoothing is supplied by the configurable digital filter in 0 to 120 seconds.
• Data integrity is ensured during power losses. Nonvolatile memory secures information.
• Keyboard security prevents accidental or unauthorized changes to process configurations.
Controller Specifications
Accuracy
Temperature stability
Input signal failure protection
Input impedance
Controller output types
Available options
Sample rate
Input filter
Wiring connections
Power consumption
Weight
Part Number
58012200
58012300
58012500
58012600
58012900
±1 digit for display
±0.01% of full span/°C change typical
Upscale, downscale or failsafe burnout
200K ohms
Electromechanical or solid state relays,
Current out
Alarm outputs, RS422/485 or ethernet TCP/IP
communications interface, Infrared
communications (standard on UDC-3500)
Input sampled 6 times a second
Off to 120 seconds
Screw terminals on rear of case
20 VA (UDC-2500) / 24 VA (UDC-3500)
maximum (90 to 264 VAC)
3 lbs.
58012900
Description
UDC-2500, Manual with Single Input (replaces UDC-2300 part number 58001200)
UDC-2500, Manual with Second Input (replaces UDC-2300 part number 58001300)
UDC-2500, Manual with Single Input and Setpoint Programming (replaces UDC-2300 part number 58001500)
UDC-2500, Manual with Second Input and Setpoint Programming (replaces UDC-2300 part number 58001600)
UDC-3500, Programmable with TSI Prom (replaces UDC-3300 controller part number 58012700)
3
TISI-12.1
Recorders
Strip Chart Recorder
The strip chart recorder is a multi-point recorder whose field worthiness
and variable configuration makes it ideally suited for on-site
applications. The standard
temperature recorder is
available with 12 channels
for reliable, accurate records
of time-temperature profiles
for all control and monitor
thermocouples. The 12-channel
model of recorder is also
available with 24 channels
(mR-20000) or as a 2-pen or
6-channel model (mR-10000).
mR-20000 (mR-10000) Specifications
Mechanical
Weight
Height
Width
Depth
Case
Door
19 lbs. (4.85 lbs.)
11 3/8 inches (5.67 inches)
Drawn steel, 16-gauge
Cast aluminum
Electrical
Voltage
Current
100 to 240VAC
1
/4-Amp at 110VAC
Configuration
Channels
Scan Rate
Paper
Dot Colors
Chart Speed
Printing
12 standard, 24 available (2 or 6)
1 1/4-seconds/channel
Z-fold, 180mm (100mm)
6 (2)
2-inch/hour factory set (1-inch/hour)
Digital and analog
Operator Interface
Although it can accommodate
a wide range of DC-voltage
45007322
inputs, each channel is
configured for Type K
thermocouples at the Team factory. Printing formats are configurable by means of a convenient menu-driven Setting mode. Chart
speed can be programmed from 0.04 to 480-inch/hour and is set for 2-inch/hour at the Team factory. In addition to chart paper, the
strip chart recorder utilizes a large, easy-to-read full dot matrix display for highly visible read selection and ease of use. Operator
input to the recorder is by means of a seven-button keypad to access and navigate the interactive Operation and Setting modes.
Digital Paperless Recorder
Team Industrial Services, Inc. also offers a digital recorder option that allows for paperless recording. The SX has a 12.1-inch, color
active matrix LCD touch screen display for clear viewing and is available with up to 48 analog inputs. The QX is another available
option with only 6 standard inputs. All collected time-temperature data can be saved to a compact flash (CF), USB storage device
reader or linked directly through the internet or LAN via an ethernet connection. The recorder includes the Trend Viewer software
necessary to view the data on a computer. Additional firmware credits are available for purchase to unlock more features if required.
SX (QX) Specifications
Mechanical
Weight
Height
Width
Depth
Case
22 lbs. (5.3 lbs.)
Mild steel, zinc-plated
Software
Processor
Operating System
RAM
Free Hard Drive
Electrical
Voltage
Current
100 to 250VAC
1
/4-Amp at 110VAC
Configuration
Channels
Scan Rate
Chart Speed
12 standard, up to 48 available (6 standard)
Real-time
Adjustable
Operator Interface
Although it can accommodate a wide range of DC-voltage inputs, each
channel is configured for Type K thermocouples at the TISI factory. The
enclosed stylus allows for easy interaction with the touch screen menus.
Using the menus, each pen can be assigned as well as alarms and chart
speeds set along with many other features. The gathered data can be
analyzed by a variety of graphs either on the LCD display or on a
computer. Other software options are available for use with a computer
that include additional features/options if required.
TISI-12.1
4
1 GHz pentium or higher
Windows 2000, XP
512 Mbyte minimum
50 Mbyte minimum
45007380
Recorders
Carrying Case
A recorder is also available as a stand-alone unit that can be installed into a carrying case. The recorder will be ‘socketed’ which
means that an enclosure will be mounted to the back and wired with the thermocouple jack panel and a power cord. The digital
recorders also include an Ethernet port. It can be plugged into any 110-volt power source and, with the use of male-to-male
thermocouple jumper cables (see page 11), will be able to provide time-temperature profiles. The carrying case is steel reinforced
with a carrying handle and lined with polyurethane foam to protect the recorder during transit and on-site use. The case has
removable front and rear doors for easy access.
45007321
Recorder, Analog, 12-point
45007322
45007380
Recorder, Digital, 12-point
45007390
45007521
Recorder, Analog, 12-point, Calibrated
45007522
45007580
Recorder, Digital, 12-point, Calibrated
45007590
45007421
Recorder, Analog, 12-point, Calibrated and Sockets
45007422
45007480
Recorder, Digital, 12-point, Calibrated and Sockets
45007490
45001800
Carrying Case (for size recorders above)
45007422 in carrying case
RECORDER REPLACEMENT PARTS
CHART PAPER
Part Number Manufacturer
45020502
Yokogawa
45020501
Yokogawa
45000302
Yokogawa
45000301
Yokogawa
45033100
Honeywell
45030900
Honeywell
45031000
Honeywell
45011900
Chino
45009800
Chino
45009801
Chino
Model
mR-1000/0
mR-1000/0
mR-180/0, 20000
mR-180/0, 20000
DPR-100
DPR-180
DPR-3000, 250
AL-3000
AH-3000
AH-3000
45007310
45007312
45007370
45007510
45007512
45007570
45007410
45007412
45007470
45001900
Recorder, Analog, 2-pen
Recorder, Analog, 2-pen, Calibrated
Recorder, Analog, 2-pen, Calibrated and Sockets
Carrying Case (for size recorders above)
Description
0-2000° Scale
0-100% Scale
0-2000° Scale
0-100% Scale
0-100% Scale
0-100% Scale
0-100% Scale
0-100% Scale
0-2000° Scale
0-100% Scale
RIBBONS & PENS
Part Number Manufacturer
45020100
Yokogawa
45020200
Yokogawa
45020300
Yokogawa
45020400
Yokogawa
45004000
Yokogawa
45033200
Honeywell
45033300
Honeywell
45030800
Honeywell
45012000
Chino
45013000
Chino
5
Model
mR-1000/0
mR-1000/0
mR-100/00
mR-1000/0
mR-180/0, 20000
DPR-100
DPR-100
DPR-180, 3000, 250
AL-3000
AH-3000
Description
Ribbon Cartridge
Red Pen
Green Pen
Purple Pen/Plotter
Ribbon Cartridge
Ren Pen
Blue Pen
Ribbon Cartridge
Ribbon Cartridge
Ribbon Cartridge
TISI-12.1
Power Source Parts
CONTACTORS
59001300
Primary Contactors (control output voltage)
59005000
Contactor, 3-pole, 90A (Standard)
59004900
Contactor, 3-pole, 120A (International)
INDICATOR LIGHTS
50000300
50000300
Indicator, Red, 80VAC with Leads
50000500
Bulb for START/STOP Switch
Secondary (Zone) Contactors
59001300
59001400*
Repair Kit for 59001300
59008500
59008700*
Repair Kit for 59008500
*Each repair kit includes:
1 - Upper Contact Assembly
2 - Lower Contact Assembly
1 - Replacement Spring
59008500
FUSES & FUSE HOLDERS
57001101
57001305
Fuse, KTK-R, 5A
57001310
Fuse, KTK-R, 10A
57001101**
Fuse, AGC, 3/4A for contactor protection
57001104
Fuse, AGC, 2A for cooling fan protection
57000102
Fuse Holder, 2P, 600V
57001700**
Fuse Holder, 30A, 250V
for contactor (3/4A) protection
50001000
50001100
50001200
LED, Bayonet-style, White
LED, Bayonet-style, Green
LED, Bayonet-style, Red
50002000
50002100
50002200
50002300
50002400
50002500
50002600
50002700
Mounting Flange for LED Assembly
Actuator Sleeve for LED Assembly
Lamp Holder for LED Assembly
Contact Block for LED Assembly
Lens Holder for LED Assembly
Green Lens for LED Assembly
Red Lens for LED Assembly
Bezel for LED Assembly
LED Assembly
62001700
50001100
SWITCHES
Part Number
62001700
62007700
57004301
57003704
CIRCUIT BREAKERS
62003801
57003704
Circuit Breaker, 1P, 5A, 277V, Rocker-style
62010100
57003800
Circuit Breaker, 3P, 125A, 600V (Cutler-Hammer) 62010400
57004102
Circuit Breaker, 3P, 125A, 600V (GE)
57004301
62010400
57004302
57004302
Circuit Breaker, Panel Mount, 3/4A
**(replaces fuse holder 57001700 with 3/4A fuse 57001101)
50000500
Description
Switch Assembly, START/STOP (Square)
Switch Assembly, START/STOP (Oval)
Switch, Pushbutton, 6-station
Aluminum Knob for 62010400
Switch, Rotary, 6-position
71001800
PANEL METERS
71001800
Ammeter, 0-300A, Digital Panel Meter
71002000
Ammeter, 0-150A, Digital Panel Meter
71002000T
Screw Terminal Adapter for 71002000
62007700
60003901
62003801
TRANSFORMERS
Primary (Main) Transformer
60000100
Transformer, 55kVA, 480 VAC (Standard)
60000710
Transformer, 55kVA, 380/415/440/480/575 VAC (International)
Secondary (120V Step Down) Transformer
60003400
Transformer, 750VA, 240-480/120-240 (Standard)
60001100
Transformer, 750VA, 208-600/120-240 (International)
60003400
TISI-12.1
60001100
Current Transformer (CT)
60003901
Current Transformer, 5-300A Loop with Leads for Panel Meter 71001800
60003902
Current Transformer, 5-150A Loop with Leads for Panel Meter 71002000
6
Power Source Parts
72000101
FANS & FILTERS
72000101
Cooling Fan, Axial
72000201
Cord for Cooling Fan, Axial, 24"
72000400
Exhaust Fan, Wire Frame, 12"
52005901
52005902
Filter, 20" x 20" x 1"
Filter, 10" x 20" x 1"
72000201
RELAYS
Part Number
59001500
59001600
59001700
57004601
72000400
ELECTRICAL CONNECTIONS
57000601
GFI Receptacle, 15A, 125V, Duplex Edison
57000602
Cover for GFI Receptacle
56012112
Terminal Block, Double Row, 12-Term
57004601
Power Distribution Block, 3P, 175A, 480V
57004603
Power Distribution Block, 3P, 175A, 600V
Description
Relay Base, 8-pin
Relay, 24VDC, 8-pin
Relay, 120VAC, 8-pin, Illuminated
59001500
57004603
59001700
LUGS
Part Number
56010400
56012200
56010304
56010306
56011605
56011610
Description
Ground Lug, Copper
Ground Lug, Aluminum
Crimp Lug, /8" Purple
Crimp Lug, 1/2" Purple
Crimp Lug, 3/8" Green
Crimp Lug, 1/2" Green
3
Crimp lugs are for cable assemblies
56010400
HARDWARE
Part Number
09002400
54009600
54012200
54012300
09003000
58005100
54008300
54008900
09002500
Description
Lever Latch for Rear Machine Door (Black)
Latch, T-Handle for Rear Machine Door (SS)
Handle for Front Door Pocket
Magnet for Front Door Catch
Control Knob for THM (Old Style)
Energy Regulator / Cycle Timer for THM (Old Style)
Handle for Top/Front of THM
Handle, Fold down for Top of THM
Feet, Rubber for THM
STRAIN RELIEF GRIPS
56006701
Strain Relief Grip, Oval, 1/2"
56006704
Strain Relief Grip, Oval, 1 1/4"
56006705
Strain Relief Grip, Oval, 1 1/2"
56006600
Strain Relief Grip, Straight, 1 1/4"
64004201
Strain Relief Grip, Mesh, 1"
64004202
Strain Relief Grip, Mesh, 1 1/4"
64004201
56006704
CASTERS
Part Number
53005200
54000401
54000403
54000404
54000411
54000413
54000414
54000413
56006600
Description
Dolly for 6-way, 4" casters (CH-style)
Rigid Caster, 4" without brake
Swivel Caster, 4" without brake
Swivel Caster, 4" with brake
Rigid Caster, 6" without brake
Swivel Caster, 6" without brake
Swivel Caster, 6" with brake
54000414
7
TISI-12.1
Power Cabling
A typical electric resistance heating circuit consists of the following components:
• A multi-zone power console (e.g. 6-way) with female camlock electrical power connectors and female thermocouple jack
panels.
• A triple cable set to bring power and thermocouple cabling from the power source to the heaters with male camlock and
thermocouple connectors on the power console end and female connectors on the heater end.
• A splitter cable to connect multiple heaters in parallel in the same zone circuit with one large male camlock connector and
multiple small female camlock connectors.
• A control thermocouple with a male polarized plug connector.
Splitter Cable
Three-way splitters are standard to enable three heaters to be connected in parallel to a single control zone. Two splitter cables are
needed for each zone. Each splitter cable connects one of the two power cables of a triple cable set to one side of the three parallel
heaters. Two-way and four-way splitters are also available.
Specifications
Length
Size
Stranding
Insulation
Ratings
4-foot long
#6, approximately 3/8-inch outer diameter
Seven bundles of 37 strands of 30-gauge
Ultra-Flex thermoplastic rubber
-74°F to 221°F, 600-Volt,
300-Amp male and 150-Amp female camlocks
29001900
29002200
Triple Cable Set
A triple cable consists of a taped assembly of twin power cables and a thermocouple extension cable. The multi-stranded power
cables are flexible and covered with a thermoplastic rubber insulation that is resistant to abrasion, oil, acid, ultraviolet light and high
temperature. The type K thermocouple extension cable is solid 20-AWG PVC-sheathed shielded wire that is encased in a PVC
abrasion-resistant jacket and equipped with a polarized male plug and female socket.
Specifications
Assembly
Length
Weight
Binding
25-foot, 50-foot or 100-foot standard
65 lbs./100-foot
Fiberglass tape, 1-foot pitch
Power Cable
Size
Stranding
Insulation
Ratings
#2, approximately 1/2-inch outer diameter
Seven bundles of 90 strands of 30-gauge
Ultra-Flex thermoplastic rubber
-74°F to 221°F, 600-Volt, 300-Amp camlocks
29004003
Thermocouple Extension Cable
Type
K, Chromel-Alumel
Size
20-AWG, Solid
Insulation
PVC with PVC outer jacket
Connectors
Polarized male plug and female socket
Part Number
29001500
29001900
29002200
Description
Splitter, 2-way, 4' long
29004001
29004002
29004003
Triple Cable Set, 25'
55002700*
55004400*
Power Cable, 4/4
Power Cable, 6/4
Additional cable is available in 10-foot increments:
Part Number
55002401
55002601
49000200
*order in 25-foot increments
TISI-12.1
8
Description
#6 Cable, Gray for Splitters
#2 Cable, Gray for Triple Cables
Thermocouple Extension Cable
Camlock Connectors
Camlock electrical power connectors achieve an insulated locking connection with an approximate 1/2-turn for high-amperage
circuits. Connector sets are available in panel mount and in-line styles.
Specifications
Panel Mount
Large In-Line
Brass male/female body, 150- or 300-Amp
Bolted neoprene casing or high-impact plastic
Brass male/female body, 300-Amp
Fiber electrical insulating sleeve
Fiber interlocking pin
Small In-Line
Brass male/female body, 150-Amp
Fiber electrical insulating sleeve
Fiber interlocking pin
Part Number
56000600
56000700
Description
Connector, 150-Amp, Male Complete
Connector, 150-Amp, Female Complete
56000400
56000500
56000600
56000700
Connector, 300-Amp, Male Complete
Connector, 300-Amp, Female Complete
Replacement Parts
56002000
Connector, 150-Amp, Male Sleeve Only
56002200
Connector, 150-Amp, Female Sleeve Only
56002300
Connector, 150-Amp, Pin
56001400
56001600
56001700
56004800
Connector, 300-Amp, Male Sleeve Only
Connector, 300-Amp, Female Sleeve Only
Connector, 300-Amp, Pin
56005300
High-Impact Plastic
56004600
Connector, 150-Amp, Panel Mount, Male
56004300
Connector, 150-Amp, Panel Mount, Female
56004800
56005300
56000400
56000500
Neoprene Casing
56004500
56004200
56004700
56000200*
*Standard on TISI 6-way machines
Female In-Line Connectors without Sleeve
56004700
9
56000200
TISI-12.1
Thermocouple
Description
To measure the surface temperature of a metallic workpiece, do not rely on contact heat transfer from your workpiece surface to the
separate junction of a sheathed or twisted-wire thermocouple. Instead get the most reliably accurate temperature measurement by
turning the workpiece surface into a thermocouple junction with the use of a capacitance discharge thermocouple welder (TAU,
Thermocouple Attachment Unit).
Operation
The TAU provides major improvements over other methods for attaching thermocouples to both ferrous and non-ferrous metals. It
attaches thermocouples directly to the workpiece and handles high temperatures, up to 2300°F, necessary for stress relieving carbon
and low alloy steels. The portable, rugged TAU can reach any job easily. The unit attaches thermocouples quickly so that heat
treating can be done promptly and the workpiece returned to use.
Cost Savings
Expensive errors occur when thermocouples are not directly attached to the workpiece and do not accurately measure the heat
treating temperatures. The TAU eliminates these errors and minimizes downtime. The penetration depth is minimal: .007 in.
(.18 mm) and .003 in. (.07 mm) in the heat-affected zone. Marring is easily removed by light filing. The TAU will alert the operator
with an audio and a visual indicator when the unit has cycled and reached the preset power level.
Specifications
Each TAU is housed in a rugged stainless steel carrying case
equipped with a padded nylon shoulder strap and designed
with storage space for the attached pliers, magnet and power
cord. Power for the solid state system is supplied by the
internal nickel-cadmium battery. The battery can be recharged
from 120-volt supply and allows up to 150 uses per charge.
Not only can the unit be operated while charging, but it can
also be completely recharged within just 3 hours.
Weight
Height
Width
Length
Battery Type
Voltage
Thermocouple
Wire Capability
Voltage Discharge
Energy Discharge
11 1/2 lbs.
8 1/2 inches
3 3/4 inches
10 1/2 inches
12V Nickel Cadmium
120VAC, 60Hz
E, J, K, T
16 - 30 Gauge (AWG)
15 - 80 Volts
5 - 50 Joules
13000300
63002200
TISI-12.1
Replacement parts for the Thermocouple Attachment Unit (TAU):
13000300
Thermocouple Attachment Unit, Series IV
13000100
Enclosure for TAU, Stainless Steel
13001000
Plier Assembly with Male Camlock for TAU
13001100
Operation Label for TAU
13005300
Adjustable Shoulder Strap for TAU
54004500
Magnet for TAU
63002200
Battery for TAU
63012300
Power Cord for TAU
10
Thermocouple
A typical thermocouple circuit consists of the following components:
• A thermocouple containing the hot junction on the workpiece surface.
It can be either a sheathed, twisted-wire or capacitance discharge welded thermocouple.
• A male polarized plug attached to the connection end of the thermocouple.
Its large diameter prong and small diameter prong avoid cross-connecting +/- leads.
• A thermocouple extension cable connecting the thermocouple to the recorder.
It has a female socket on the thermocouple end and a male plug on the recorder end.
• A recorder or similar measuring instrument to indicate and/or document the temperature value.
A polarized female jack panel is needed to accept the thermocouple extension cable.
There are a variety of types of thermocouple wire with different metallic combinations; however, type K Chromel-Alumel wire, with
a temperature range of 32°F to 2300°F, is best suited for most of the thermal processes conducted in heat treating. The Chromel
element is the non-magnetic positive lead with yellow insulation. The Alumel element is the magnetic negative lead with red
insulation.
In addition, there is a variety of individual wire insulation and overall jacket materials. Q/Q (braided quartz glass insulation and
jacket) is an excellent choice for most applications because of its abrasion and temperature resistance. Cefir (braided ceramic fiber
insulation and jacket) is appropriate for extreme temperature applications.
Specifications
Type
K (Chromel-Alumel)
Wire
20-gauge (AWG)
Maximum Range
Q/Q
1200°F, continuous (1600°F, single)
Cefir
2200°F, continuous (2400°F, single)
Quality
Certificate of Conformance
Part Number
49000200
49000500
49000600
Description
Wire, K TC, Extension with PVC shielded jacket
Wire, K TC, Q/Q
Wire, K TC, Cefir
49000600
49000500
TISI has a variety of thermocouple extension wires and cables available as well as connectors and jack panels. The extension wire
has a PVC wire insulation and shielded jacket. All standard parts are Type K, 20-gauge (AWG) but other types and sizes are
available. Contact your TISI sales representative for more information.
Part Number
49004003
49004004
49004005
Description
TC Cable Assembly, K TC Extension with Male and Female Connectors, 25'
49004203
49004202
TC Cable Assembly, Jumper, K TC Extension with Male Connectors, 6'
TC Cable Assembly, Jumper, K TC Extension with Male Connectors, 10'
49004100
TC Cable Assembly, K TC Q/Q with Male Connector, 10'
49000900
Part Number
49000900
49001000
49008100
49008200
49004003
Description
Plug, TC, Type K
Socket, TC, Type K
Plug, TC, Type K, Midget
Socket, TC, Type K, Midge
49004202
49001000
11
TISI-12.1
Thermocouple
Unlike thermocouple wire, sheathed thermocouples can not be capacitance discharge-welded to workpiece surfaces. They must be
attached to the work surface with welded clips or banding, both available from TISI.
Specifications
Construction
Thermocouple wire within metal sheath, hollow
Filled with magnesium oxide, grounded junction
Sheath Material
310 Stainless Steel, standard
Inconel, 304 or 316 Stainless Steel available, custom
Sheath Diameter
/8-inch, standard
0.04-inch to 3/8-inch available, custom
Length
2-foot, 6-foot, 12-foot and 20-foot, standard
Other lengths available, custom
Attachment
/8-inch, standard
Stainless or mild steel available, single or dual
(dual available in stainless steel only)
1
1
49001800
Part Number
49002202
49002206
49002212
49002220
49001900
49002220
Description
TC Sheathed, 2', 1/8-inch diameter, Type K
49002000
49001800
49001900
Clip, Single TC, Mild Steel
Clip, Single TC, Stainless Steel
Clip, Dual TC, Stainless Steel
37000100
Putty, Moldable, 11 oz. Tube
49002202
Part Number
49001101
49001102
49001103
49001105
49001106
49008001
49008004
49008005
49008010
49008011
49008002
49008003
49008012
Description
TC Jack Panel, 2-point, Screw-mount
49001103
TC Jack Panel, Numbered 1-2, Self-mount
TC Jack Panel, Numbered Dual 1, Self-mount
TC Jack Panel, Numbered Dual 2, Self-mount
TC Jack Panel, Numbered Dual 1-6, Self-mount
49008010
49008012
TISI-12.1
12
Test Equipment
The TC-100 is a thermocouple simulator which can source or measure ten common thermocouples (J, K, T, E, R, S, B, L, U, C) as
well as mV. Features include high accuracy (±0.3°C for Type J), source resolution of 0.1°F/C and MIN/MAX recall in measure
mode. Three setpoints can be set per thermocouple which are easily set utilizing the arrow buttons and knob control. Connections
can be made either via a mini-plug or bare wires to the terminals. The calibrator is protected with a rugged, shock-resistant case and
comes with a protective rubber boot to prevent damage if dropped. Unit has input protection up to 240 VAC.
Specifications
Mechanical
Weight
Length
Width
Depth
Case
Accessories
Electrical
Input Voltage
Program
Calibration
Measure
Range
Accuracy
Connection
65002100
12 ounces (0.75 lbs.)
5.7 inches
3.15 inches
1.43 inches
Shock resistant ABS
Protective rubber boot, battery and charger (sold
separately)
-10 to +75.000 mV, 1 mV resolution
9V-battery (alkaline or NiCad rechargeable)
Program
J, K, T, E, R, S, B, L, U or C thermocouples, mV
-392 to 2501°F (-200 to 1372°C) for Type K
±0.35-0.6°C (based on range), 0.1°F/C resolution
Internal or external cold junction compensation,
mini-plug or bare wires
Three setpoints for each TC type, Knob control
Part Number
65002100
65002100A
65002100B
Description
Temperature Calibrator, Martel TC-100
AC Adapter for use with Rechargeable Battery
Rechargeable NiCad 9V Battery
According to our company standards, calibration of our equipment is
required every six months. Team Industrial Services, Inc. provides
calibration services for all applicable equipment. Please contact your
sales representative for more information.
The standard Brinell kit includes the following in a carrying case:
• Large Bar Holder
• Five Random Test Bars
• Scope
• Computing Wheel
• Computation Pad
The large bar holder can be substituted for a fillet weld tester or
the fillet weld tester can be purchased separately.
13005001
13005001
Brinell Kit with Large Bar Holder
13005002
Brinell Kit with Fillet Weld Tester
13007600
Fillet Weld Tester
13006600
Scope
13005102
Brinell Bar, 176 Hardness
13005105
13005108
Other size hardness bars available
13
TISI-12.1
Heaters
Construction
Flexible ceramic pad (FCP) heaters are manufactured by weaving multi-stranded 80/20 Nichrome electric resistance heating wire
through passages within interlocking ceramic beads. The beads are molded from sintered 94% Alumina ceramics, more that 3/8-inch
thick. The Alumina has excellent high-temperature dielectric properties which combined with the interlocking bead design provide
FCP heaters with exceptional electrical insulating qualities.
Flexibility
The interlocking bead design imposes rigidity along the heater length while allowing flexibility along the heater width, enabling it to
conform to the curved surfaces of pipes and pressure vessels. A nominal nine-inch length of nickel wire is welded to each end of the
Nichrome wire to create a cold tail to prevent the electrically insulated camlock connectors from being heated.
26001301
Thermal Power
FCP heaters are generally available to two standard values: 80VAC, which are the most common, and 60VAC. Custom designed
heaters, however, can also be provided. All 80VAC heaters are rectangular with a surface area of 120 square inches and a thermal
power of 3.6 kW, producing a power density of 30 W/in2 with an electrical current of 45 amps. The 60VAC counterparts are simply
three-quarters the size of an 80VAC pad with a surface area of 90 square inches and a 2.7 kW thermal power but with the same
power density and electric current. All 80VAC heaters can be run on 60VAC, but their kW output is reduced from 3.6 to 2. Their
rectangular shapes are available in the following variety of width and length combinations.
80VAC HEATERS
Part
Number
26000701
26000801
26000901
26001001
26001101
26001201
26001301
26001401
26001501
26001601
26001701
26001801
26001901
26002001
TISI-12.1
Type
CP3
CP4
CP6
CP8
CP10
CP12
CP15
CP18
CP21
CP24
CP29
CP36
CP72
CP120
Width (A)
(Inches)
3
4
6
8
10
12
15
18
21
24
29
36
72
1
60VAC HEATERS
Part
Number
26002101
26002201
26002301
26002401
26002501
26002601
26002701
26002801
26002901
26003001
26003101
26003201
Height (B)
(Inches)
39
29
19 1/2
14 1/2
12 1/2
9 3/4
8
6 1/2
5 3/4
5
4
3 1/4
1 3/4
120
14
Type
CP3
CP4
CP6
CP8
CP10
CP12
CP15
CP18
CP21
CP26
CP52
CP87
Width (A)
(Inches)
3
4
6
8
10
12
15
18
21
26
52
1
Height (B)
(Inches)
28 1/2
21
14 1/2
10
9
7 1/4
5 3/4
5
4
3 1/4
1 3/4
87
Heaters
Features
Because of their design and components, FCP heaters have the following benefits:
• Durability - The ductility of multi-stranded Nichrome wire means a longer heater life
• Uniformity - Evenly woven wire means temperature uniformity throughout the heater
• Ruggedness - Abrasion resistant ceramic means heaters withstand rough handling
Variations
Due to the availability of different bead configurations and different grades and gauges of electric resistance wires, a variety of
custom heater designs can be made available:
• Shapes - Combinations of rectangles, trapezoids and triangles
• Fingers - Non-interlocking designs that can conform to conical workpiece surfaces
• Higher Temperature - Special heaters for temperatures up to 2300°F
• Sizes - Smaller heaters that can be connected in series for standard voltages
• Voltages - Different size heaters can be made for non-standard voltages
• Reconditioned - Lower cost heaters are available, manufactured with used ceramic beads
• Insulated Pads - FCPs can be assembled to custom mesh mats for insulated modules
Custom heaters are available, contact your TISI sales representative for more information.
26009600
51000100
51000300
51000600
51000500
51000200
Replacement parts for the FCP Heaters:
26010500
60V FCP Heater Repair Kit
26010600
80V FCP Heater Repair Kit
51000100
51000200
51000300
51000400
51000500
51000600
Body Bead, Standard
Body Bead, Standard with Hole
End Bead, Male
End Bead, Female
Tail Bead, Pink
Tail Bead, White
26009602
26009600
55001500
55001600
60V Heater Core Wire Assembly
Wire, 80/20 Nichrome Heater Body
Wire, Nickel Cold Tail
51000400
Description
Body Bead, Standard
Body Bead, Standard with Hole
End Bead, Male
End Bead, Female
Tail Bead, Pink
Tail Bead, White
Connector, 150A Male Power
15
80VAC Kit
Quantities
5
125
10
50
50
50
10
10
60VAC Kit
Quantities
5
85
8
35
35
35
10
10
TISI-12.1
Insulation
Components
A thermal insulating system has two primary components: the insulation material and the means to secure the insulation to the
surfaces of the workpiece. Team Industrial Services, Inc. is a source of supply for a variety of products in both component categories.
InsulationMaterial
Thermal insulation is available in a wide variety of materials and forms. TISI makes
available those materials and forms that are best suited for on-site thermal processing
because of their cost effectiveness in application and heat loss prevention.
RCF
Refractory ceramic fiber (RCF) blanket is the most widely used insulation for elevated
temperature applications and is available in various thicknesses, widths and densities.
However, mineral wool delta board is the most cost sensible option for single-use
applications.
Non-RCF
Superwool (Silica) is a non-RCF blanket alternative. Needled silica mat insulation blanket is a non-RCF product that is constructed of
98% amorphous silica, whose construction imparts fiber integrity for high temperature reusable applications. Cooperknit is a
silica-based knitted textile that offers the advantage over other types of insulation because the fabric does not break down preventing
harmful airborne particles and can be reused without any significant deterioration.
Part
Number
37000900
37000800
37000700
37000200
37012500
37003500
37003600
37004500
37009600
37009300
Material
RCF
Thickness
Width
Length
Density
Limit
Ceramic Fiber
Ceramic Fiber
Mineral Wool
Superwool
Superwool
Needled Silica
Needled Silica
Welding Cloth
Welding Cloth
Cooperknit
Yes
Yes
Yes
No
No
No
No
No
No
No
1-inch
1-inch
2-inches
1-inch
1-inch
1
/2-inch
1
/2-inch
.030-inches
.060-inches
1
/2-inch
2-foot
2-foot
4-foot
2-foot
2-foot
2-foot
3-foot
3-foot
3-foot
2-foot
25-foot
6 lb/ft3
25-foot
8 lb/ft3
24-foot
8 lb/ft3
25-foot
6 lb/ft3
25-foot
8 lb/ft3
25-foot
8 lb/ft3
25-foot
8 lb/ft3
150-foot 18 ounce
150-foot 36 ounce
25-foot 15.2 lb/ft3
1800°F
1800°F
1000°F
2200°F
2200°F
2000°F
2000°F
2300°F
1800°F
2000°F
Team Industrial Services, Inc. manufactures a variety of standard and custom insulation mats in which the insulating material
(Ceramic Fiber or Needled Silica) is encased in a stapled or stitched protective outer layer of stainless steel-knitted mesh or high
temperature silica welding cloth respectively. Cooperknit is also available as mats but does not require an outer protective layer.
The material is cut to size and sewn at both ends.
Product
Size
MeshedMat
encased in SS mesh
1' x 2'
1' x 3'
1' x 4'
1' x 6'
2' x 2'
2' x 3'
2' x 4'
2' x 6'
2' x 8'
2' x 10'
2' x 12'
MeshMat
6lb.
37007802
37007803
37007804
37007806
37007902
37007903
37007904
37007906
37007908
37007910
37007912
PartNumbers
MeshMat Insulation
8lb.
Pad
37008002
37022002
37008003
37022003
37008004
37022004
37008006
37008102
37022102
37008103
37022103
37008104
37022104
37008106
37008108
37008110
37008112
-
Cooperknit
Mat
37009402
37009403
37009404
37009406
37009408
37009410
37009412
InsulationPad
encased in silica cloth
Additional sizes are also available, contact your TISI sales representative for more information.
TISI-12.1
16
Insulation Attachment
Insulation is secured to workpiece surfaces by means of steel banding or capacitance discharge-welded studs or pins and retaining
clips. TISI is a source for banding and installation tools as well as insulation studs, pins, retaining clips and stud welders. All stud
welding pins and clips are 12-gauge. Other sizes are available, contact your sales representative for more information.
Part Number
54000102
54004202
Description
Banding, Mild Steel, 1/2", 300'/roll
Clips, Wing, Mild Steel, 1/2"
54004302
54004402
Banding, Stainless Steel, 1/2", 200'/roll
Clips, Wing, Stainless Steel, 1/2"
13003000
54008600
55004700
Banding Tension Tool
Fiberglass Tape, 3/4", 250'/roll, 48 rolls/case
Wire, Iron Tie, 16-gauge, 3.5 lbs./roll, 20/case
54010501
54010503
54010700
54010710
54013402
54013502
Eagle Stud Welder
Weight
Height
Width
Depth
Weld Rate
Weldable Materials
Pin/Stud Range
Weld Voltage
Capacitance
Weld Mode
Power Requirement
Part Number
13002803
13006417
13006401
13006414
13006402
13003000
54004402
54004302
Part Number
54010501
54010502
54010503
54010504
Description
Pin, Stud Welder, 3", Mild Steel, Pointed
Pin, Stud Welder, 6", Mild Steel, Pointed
Pin, Stud Welder, 3", Mild Steel, Blunt
Pin, Stud Welder, 6", Mild Steel, Blunt
54010401
54010402
54010403
54010404
Pin, Stud Welder, 3", Stainless Steel, Pointed
Pin, Stud Welder, 6", Stainless Steel, Pointed
Pin, Stud Welder, 3", Stainless Steel, Blunt
Pin, Stud Welder, 6", Stainless Steel, Blunt
54010702
54010712
Clip, Stud Welder, 1.5", Mild Steel, Round
Clip, Stud Welder, 2.5", Mild Steel, Square
54010700
54010710
Clip, Stud Welder, 1.5", Stainless Steel, Round
Clip, Stud Welder, 2.5", Stainless Steel, Square
54013401
54013402
54013403
Lacing Anchor, without pin, Stainless Steel
Lacing Anchor, 2.5", Stainless Steel
Lacing Anchor, 4.5", Stainless Steel
54013501
54013502
54013503
Pin, Quilting, 1.5", Stainless Steel
26 lbs. (without gun and cables)
8 1/2 inches
10 inches
13 inches
Up to 20/minute
Mild and Stainless Steel, Aluminum
14-gauge through 1/4" diameter weld base
35-175VDC
70,000 Mfd
13006402
Contact
115VAC, 60 Hz, 20-Amp
Description
Stud Welder, Eagle
Collet, Bullet-style (no stop required)
Collet, ‘B’ (requires stop - 13006414)
Stop for ‘B’ Collet
Collet Protector
13006401
13006414
13006417
17
TISI-12.1
THE WORLD’S MOST COMPLETE
SPECIALIZED
INDUSTRIAL SERVICES
Valve Repair Services
Hot Tap Services
Field Machining
Services
Technical Bolting
Services
Pipe Repair Services
NDE/NDT Inspection
Emissions Control
Services
Field Heat Treating
Leak Repair Services
Turnaround Services
Pipeline Services
Training
The right people, technology and experience to keep
your plants online and in production

Twin Heat Module

Transcription

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